Log Entries for Miscellaneous
Log Entry Date: May 8, 2007
Miscellaneous
Taxi LIght
6. hours
Yesterday and today I continued working on the installation of the DuckWorks taxi light in the left wing leading edge. I started by using the supplied template to locate two holes in each of the ribs that define the bay for the light. These are initially drilled to #30 (use the 12" drill for the inboard rib through the lightening holes) so that 10-32 plate nuts can be cleco'ed in place. This then allows the plate nut #40 mounting holes to be match drilled.. The screw hole is enlarged to size and using the supplied 3/32 blind rivets, the platenuts are riveted in place.
Next, the plate that mounts the light is prepared. This consists of riveting two plate nuts in to pre-punched holes that hold the lamp. Then the plate is cut to length so it can fit in the bay. You cut off the outboard flange, trimming the plate to length. Then the flange that was cut off is riveted back on to the shortened plate. Mount the lamp and temporarily mount the plate/lamp assembly in to the bay.
I am now in the process of trimming the lens for match drilling to the 6 holes through the skin that I drilled Sunday. The lens is trimmed on the top and bottom end to allow 1" excess beyond the corresponding edges in the leading edge hole and 5/8" on either side. Corners are rounded allowing sufficient edge distance around the to-be-drilled mounting holes. It was about 70 degrees in the shop today. Plenty warm enough to work with the plexiglas lens.
I made the rough cuts with a cut-off wheel in my Dremel and then a belt sander to take it down to the edges. This is where I finished the day. I am getting it down to shape. Next, I need to finish the edges and get it ready to match drill to the mounting holes through the skin. I've ordered plexi-drills from Avery Tools for this job.
Yesterday and today I continued working on the installation of the DuckWorks taxi light in the left wing leading edge. I started by using the supplied template to locate two holes in each of the ribs that define the bay for the light. These are initially drilled to #30 (use the 12" drill for the inboard rib through the lightening holes) so that 10-32 plate nuts can be cleco'ed in place. This then allows the plate nut #40 mounting holes to be match drilled.. The screw hole is enlarged to size and using the supplied 3/32 blind rivets, the platenuts are riveted in place.
Next, the plate that mounts the light is prepared. This consists of riveting two plate nuts in to pre-punched holes that hold the lamp. Then the plate is cut to length so it can fit in the bay. You cut off the outboard flange, trimming the plate to length. Then the flange that was cut off is riveted back on to the shortened plate. Mount the lamp and temporarily mount the plate/lamp assembly in to the bay.
I am now in the process of trimming the lens for match drilling to the 6 holes through the skin that I drilled Sunday. The lens is trimmed on the top and bottom end to allow 1" excess beyond the corresponding edges in the leading edge hole and 5/8" on either side. Corners are rounded allowing sufficient edge distance around the to-be-drilled mounting holes. It was about 70 degrees in the shop today. Plenty warm enough to work with the plexiglas lens.
I made the rough cuts with a cut-off wheel in my Dremel and then a belt sander to take it down to the edges. This is where I finished the day. I am getting it down to shape. Next, I need to finish the edges and get it ready to match drill to the mounting holes through the skin. I've ordered plexi-drills from Avery Tools for this job.